Motor Vehicle Control Unit Connector Pin Fixation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control units for printed circuit board elements face challenges with long connector pins that require complex and expensive tools for installation, leading to tolerance issues and increased material costs due to the need for large housing dimensions to accommodate thermal expansion, resulting in a bulky and costly design.
Innovation Solution
A control unit design featuring straight connector pins fixed only in the printed circuit board element, with a first encapsulation layer encasing the pins to prevent bending forces and reduce material costs, allowing for a compact and flat structure by eliminating the need for direct fastening in the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long connector pins are pressed or fixed into the housing or connector receptacle, then the connector pins can be electrically connected, but complex and expensive tooling is required and tolerances deteriorate due to wear
Solution Approach 1:
The invention extracts the connector pin fixation function from the housing/connector receptacle and relocates it entirely to the printed circuit board element. The connector pins are now only pressed or soldered into the PCB, eliminating the need for separate housing fixation mechanisms and the associated complex tooling.
Solution Approach 2:
The printed circuit board element acts as an intermediary that provides both electrical connection and mechanical fixation for the connector pins. By integrating both functions into the PCB, the invention eliminates the need for complex housing-based fixation tooling while maintaining reliable electrical and mechanical connections.
2Reliability
If the distance between the housing and the circuit board element is increased to reduce bending stresses on connector pins, then connection reliability improves, but the control unit height and volume increase
Solution Approach 1:
The invention extracts the mechanical fixation function from the housing and transfers it to the PCB. This allows the connector pins to be short since they only need to bridge the gap between the PCB and connector, not extend into the housing. The housing is no longer structurally dependent on long connector pins for assembly.
Solution Approach 2:
Instead of using the housing to support and position connector pins (which requires long pins and large distances), the invention inverts the approach by having the PCB support and position the connector pins. This reversal enables compact design with minimal distance between PCB and connector.
3Stability of the object's composition
If the distance between the housing and the circuit board element is increased to accommodate thermal expansion differences, then bending stresses on connector pins are reduced, but material costs and volume increase
Solution Approach 1:
The invention extracts the thermal expansion accommodation function from the mechanical structure (housing-connector-pin assembly) and transfers it to the electrical connection interface (PCB-connector interface). The PCB and connector are designed to work together as a thermal expansion couple, eliminating the need for large structural clearances.
4Strength
If connector pins are fixed in both the housing and the circuit board element, then mechanical stability is improved, but the risk of connection failure due to bending forces increases
Solution Approach 1:
The invention extracts the mechanical fixation function from the housing and concentrates it entirely in the PCB. This creates a single-point fixation system where the PCB provides both electrical connection and mechanical support, eliminating the bending forces that occur when pins are fixed at multiple points (housing and PCB).
Solution Approach 2:
The PCB serves itself by providing both electrical connection and mechanical fixation functions. The same PCB that receives electrical signals also provides the mechanical support and positioning for the connector pins, eliminating the need for separate housing fixation and the associated bending stress problems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures secure fastening of connector pins against bending forces, reduces material costs, and minimizes the control unit's volume by allowing a smaller distance between the housing and the printed circuit board element, thereby enhancing cost-effectiveness and structural integrity.
Implementation Method 1
a first potting layer is applied at least partially to a first side of the circuit board element in such a way that the first potting layer completely encloses a partial area of the connector pins
Data Source
Figure 1~3
Figure 4~7
AI summary
The invention relates to a control unit (10), in particular for a motor vehicle, which control unit comprises: a circuit board element (30) having electrical components (35, 36, 37) arranged on a mounting surface (32) of the circuit board element (30), a housing (20), in which the circuit board element (30) is arranged, and a plurality of linear connector pins (40-43) for connecting a female connector, wherein the connector pins (40-43) are each electrically connected to one or more of the electrical components (35, 36, 37), wherein the connector pins (40-43) are fastened in the circuit board element (30) and are not fastened directly in the housing (20).